Boiler feedwater treatment

Fundamentals

The service life of pipes, boiler systems, pumps and fittings in thermal hot-water
and steam-boiler systems is determined to a great extent by the quality of the
boiler water.
Water contains different amounts of oxygen (O2) and carbon dioxide (CO2), de-
pending on the pressure and temperature. Both gases cause damage to metallic
boiler materials in a specific way: oxygen is oxidative and carbon dioxide (carbo-
nic acid) is aggressive.

Oxidation/ The O2 corrosion leads to partial, wheel-shaped lines and holes. Over time, these lines
Corrosion corrosion become pits with edges that generally grow together. The oxidised material
problem then often problem fills the lines and holes.
The CO2 corrosion, on the other hand, attacks the surface evenly.

Both forms of corrosion can endanger the operating safety of a boiler unit considerably,
depending on the pressure and temperature levels.

The The specific degassing methods are therefore used to remove the two gases, oxygen and
degassing degassing carbon dioxide, from the water or to reduce them to below the respective re-
solution quired solution residual concentrations (guaranteed value to be complied with).

The guaranteed value is defined as the remaining quantity of oxygen or carbon dioxide
that continually reaches or undershoots degassing in the middle of a longer operational
stage.

The process of thermal degassing is highly suitable for removing dissolved gases from the
water.

Thermal degassing unit for heating stations, power stations and other steam-boiler systems

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 Boiler feedwater treatment

Processes for degassing

The technical removal of troublesome, gaseous contents in general is called ”de-

gassing“.
Deacidification or neutralisation is the technical removal of free, aggressive CO2,
since it is tied to an increase in the pH value of the water.

Degassing A differentiation is made between two processes for the degassing of gaseous contents
process in the field of water treatment: thermal degassing and chemical degassing.

Requirements for the quality of the feedwater and boiler water in the steam generator
are contained for example in the TRD 611 (TRD = German Technical Regulations for
Boilers).

Thermal Thermal degassing of feedwater to separate out the dissolved and corrosive gases
degassing contained within requires that the water be boiling. In this state, the solubility of gases
in liquids lies near zero. Fine distribution via cascading spraying plates has a supportive
function here. Degassing can occur in over- or underpressure.

The mixture of condensate and fresh water is fed into the degassing dome at the top.
Heating up to the boiling temperature occurs with heating steam, which flows into the
degassing unit at the bottom and flows upward against the current. The gasses driven
out as a result are lead away with the exhaust vapours via the exhaust vapour outlet in
the degassing dome.

The degassed water is collected in the feedwater reservoir.

Thermal degassing often occurs at temperatures minor above 100°C and operating
pressures around 0.2 to 0.3 bar (g). Thus an oxygen content under 0.02 mg O2/L and a
carbon dioxide content of less than 1 mg CO2/L are possible in the feedwater.

Chemical Chemical degassing or residual degassing occurs through the addition of chemicals.
degassing These chemicals are dissolved in dilution water (minimum soft water quality, depending
on water treatment) and are suitable for removing or converting the oxygen contained
in the water. The reaction time differs when different chemicals are used. In general, the
greater the water temperature, the shorter the reaction time.

Some of these chemicals have almost no side effects apart from a minimal increase in
harmless salts, while other chemicals form free acids that decrease the alkalinity. Another
group form steam-volatile alkaline substances during heating, which are effective beyond
the boiler to the steam and condensate network.

The addition of the chemical solution for removal of remaining oxygen occurs together
with any required corrective chemicals for stabilisation of remaining hardness, alkalisation
etc.. Dispensing occurs with suitable dosing equipment (dosing pump, chemical draw-in
dosing device etc.).

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 Thermal degassing
Fundamentals

Description of process

A degassing system consists of several components

• Degassing unit (degasser)
• Feedwater tank
• Control unit (device)
• Safety unit (device)

Exhaust vapours

Condensate Supplementary water /

Degassing Soft water
unit

Dosing system
Feedwater tank

Steam pressure P
regulator

Heating steam Feedwater pumps

Steam Steam generator

Power/Energy Feedwater treatment

with thermal degassing

Degassing The degassing unit is an upright, cylindrical vessel made of austenitic steel. An internal
unit steam distribution system ensures direct contact of the heating steam with the medium to
be degassed.

The feedwater, a mixture of condensate and supplementary water, is fed into the top sec-
tion of the degassing unit via the respective connection nozzles. Even, fine distribution of
the water over the entire width of the degassing unit occurs via trickling with a surge tank
and several cascade plates. The water trickles downward in drops or fine jets, is caught by
the cascade plates, redistributed and finally collected in the feedwater reservoir.

Steam flows against the water from all sides via the distribution system built into the
degasser. The water heats to the boiling temperature very quickly as a result of the large
surface created via trickling. The large surface benefits the outgassing of oxygen and free
carbon dioxide. These gases are taken up and carried out by the steam flow and removed
from the degasser at the exhaust vapour outlet in the top level of the degassing unit via
the interior operating pressure. The fixtures are equipped with openings for guiding the
steam.

The exhaust vapour quantity is limited at the exhaust vapour connection nozzles via a
throttle mechanism (e.g. orifice, throttle valve).

The degasser is normally placed directly on the feedwater tank.

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 Thermal degassing
Fundamentals

Feedwater The feedwater tank is manufactured as a horizontal, cylindrical vessel, usually made of
tank unalloyed and normally annealed steel.

Its main task is the storage of feedwater for the supply of the boiler system. It also fulfills
a series of tasks that are of decisive importance for the entire treatment and economical
operation. It serves:

• to cover peaks of demand of the boiler water supply

• to compensate for varying quantities of condensate
• to bridge disruptions or interruptions of the water supply
• as a reaction vessel for supplementary chemicals
• for connection of control units, measuring devices and safety devices.

The supply height to the boiler feed pumps appropriate for the water temperature is de-
cisive for the height of the tank. The tank is attached via thrust blocks to the installation
side.

Feedwater degassing must be protected against overpressure, underpressure and overfil-

ling and is also equipped with level, temperature and pressure indicators.

Constant boiling up of the vessel content achieves subsequent degassing in the feedwa-
ter tank. This further improves the water quality. The heating steam supply is need-based
and occurs via a control unit.

Control of If the heating steam has a higher pressure than the plant operating pressure, a steam
degassing pressure regulator must be installed in the steam supply line to the degassing unit. The
system regulator is controlled solely based on pressure.

The required heating steam quantity depends on the quantities of additional water and
condensate fed in and their temperature level. Regulation of the steam supply occurs
automatically.

The degassing system must be set to an operating pressure exceeding the boiling point
of the water at atmospheric pressure. This operating pressure (e.g. 0.2 bar (g)) serves as
the impulse for control of the steam quantity to be supplied.

To keep the water stock in the feedwater tank as constant as possible, automatic supply
control of the supplementary water occurs depending on the water level in the tank. The
control unit is often connected directly to the feedwater tank.

To prevent sudden loads on the system and the supply network for water, steam, hot
water and electricity, supply control must occur as smoothly as possible.

The level sensors, i.e. floats, electrodes, floating switches and the like, are to be set so
that enough space remains between the set water level and the overflow of the vessel so
that condensate return peaks can be caught.

The resulting condensate (free of oil, hardness and other impurities) is fed back to the
feedwater vessel or degassing unit as evenly as possible.

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 Thermal degassing
Fundamentals

Safety devices The feedwater reservoir must be protected against overfilling and overpressure. A safety
valve is used to prevent overpressure, and overflow regulation is used for overfilling.

Units carrying a possible risk of vacuum build-up due to the method of operation and
construction must be protected by at least one vacuum breaker.

This is usually a non-return valve that is closed due to overpressure in the degassing unit
or feedwater tank and opened upon the presence of a vacuum from the external over-
pressure. The vacuum is broken via the aeration of the vessels.

Operation If used properly, clearly visible steam vapours can be seen to exit the exhaust vapour
output of the degassing unit.

The exhaust vapour quantity (depending on the nominal load) is measured via the vapour
throttle at the vapor connection nozzle of the degassing unit in such a way that freed
oxygen and carbon dioxide can be lead away to the outside air. Proper degassing is only
ensured when the exhaust vapours can be released unhampered.

The degassing unit temperature and pressure must be monitored continuously.

Complete RWT GmbH dimensions, manufactures and supplies complete units for the treatment of
units – boiler feedwater.
Design,
In addition to the main components, RWT GmbH also supplies all the fittings, regulators,
manufacture
safety equipment, dosing units, sample coolers and examination cabinets, boiler water
and
flash traps and condensate vessels required for operation and the necessary steel support
installation
structures.
Only high-quality materials from well-known manufacturers are used.

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 Thermal degassing
Checklist

Project name:

Customer:
Name

Street Post code, City

Phone Fax

E-mail www

Project
Name
management:

Street Post code, City

Phone Fax

E-mail www

Water analysis:
Chemical/physical analysis existent:  yes, see appendix Biological analysis:  yes, see appendix

Design data:
Pre-treatment existent:  no
 yes, which

Required degassing output: ___________ m³/h Boiler type/Manufacturer: _______________________

Steam output of boiler system: ___________ kg/h ______________________________________________
Heating steam: Pressure ___________ bar Temp. ___________ °C
Condensate: Pressure ___________ bar Temp. ___________ °C
Supplementary water: Pressure ___________ bar Temp. ___________ °C
Operating time per day: ___________ h ______________________________________________
Installation place available:  no
 yes Length _____________ Depth _____________ Height _______________

Remarks:

u:\pmrwt\kata\R4i1\R4i1_CMYK_EN 10/2012
RWT GmbH • Erlenweg 42 • D-33335 Gütersloh • Tel.: +49 5241 97 60 0 • Fax: +49 5241 97 60 50
www.hydrogroup.de